Miller Blue Star 3500 - Manuals

OM-498 Page 2 Return To Table Of Contents Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metalobjects can...

OM-498 Page 3 Return To Table Of Contents STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at overflow tank, if pres-ent on unit, instead of radiator (unless told otherwisein maintenance section or engine manual). If th...

OM-498 Page 4 Return To Table Of Contents READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and service according to this manualand the engine/air compressor (if applicable) manu-als. H.F. RADIATION can cause interference...

OM-498 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédurep...

OM-498 Page 6 Revenez à la table des matières LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-rateur d’adduction d’air homologué....

OM-498 Page 7 Revenez à la table des matières L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protection lors d’une in-tervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles debatterie....

OM-498 Page 8 Revenez à la table des matières LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sousrisque d’endommager le moteur électrique à caused’une tension et d...

OM-498 Page 9 Return To Table Of Contents SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Engine Choke Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds Time Protective Earth (Ground) Circuit Breaker T...

OM-498 Page 10 Return To Table Of Contents 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) D Depth 31-1/4 in (793 mm) Do not exceed tilt angles or engine could A 31-1/4 in (793 mm) B Do not exceed tilt angles or engine couldbe damaged or...

OM-498 Page 11 Return To Table Of Contents 4-4. Fuel Consumption (Honda-Powered Units) 802 121 Continuous Welding 4-5. Duty Cycle 802 092 Duty cycle is the percentage of 10minutes that unit can weld at ratedload without overheating. Exceeding duty cycle candamage unit and voidwarranty. 100% Duty Cyc...

OM-498 Page 12 Return To Table Of Contents 4-6. Generator Power Curve 802 129 The ac generator power curvesshow the generator power availablein amperes at the receptacles. 4-7. Volt-Ampere Curves 198 453 The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe...

OM-498 Page 13 Return To Table Of Contents SECTION 5 − INSTALLATION 5-1. Installing Welding Generator install1 5/02 − 802 512-A / Ref. 151 556 / 158 936-A / 800 652-A / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location 5-2. Groun...

OM-498 Page 14 Return To Table Of Contents 5-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device asstated in electrical codes. 2 3 800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to...

OM-498 Page 16 Return To Table Of Contents 5-7. Connecting To Weld Output Terminals 196 921 / 495 179 1 Positive (+) Weld OutputTerminal 2 Negative (−) Weld OutputTerminal For Direct Current Electrode Posi-tive (DCEP), connect work cable toNegative (−) terminal and electrodeholder to Positive (+) te...

OM-498 Page 17 Return To Table Of Contents SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (Kohler-Powered Units) 802 512-A / 495 179 5 2 60 Hz 3 4 Weld and generator power output stops ifgenerator overheats or engine speed istoo low. 1 Engine Switch Use switch to open ignition circuit, an...

OM-498 Page 19 Return To Table Of Contents 6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) Weld and generator power output stops ifgenerator overheats or engine speed istoo low. 1 Engine Switch On models with recoil-start, use switch toopen ignition circuit, and to stop engine. ...

OM-498 Page 20 Return To Table Of Contents SECTION 7 − OPERATING AUXILIARY EQUIPMENT The welding generator provides power while welding and with the Current controlin any position. However, under these conditions equipment connected to thewelding generator may be subject to larger than normal voltag...

OM-498 Page 21 Return To Table Of Contents 7-2. Optional Generator Power Panels Ref. ST-802 124 / H-495 290 / H-495 283 Generator Power Panel 495 315 (USA) Generator Power Panel 495 279 (Canada) Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia) If unit does not h...

OM-498 Page 22 Return To Table Of Contents 7-3. Generator Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of allreceptacles. NOTE Total power from generator NOT to exceed 3500 Watts (60 Hz) Receptacle Protected By Panel 495 218 (USA) Panel 495 315 (USA)...

OM-498 Page 24 Return To Table Of Contents SECTION 8 − MAINTENANCE 8-1. Routine Maintenance Recycle engine fluids. Stop engine before maintaining. See Engine Manual and Maintenance Label.Service more often if used in severe conditions. * To be done by Factory Authorized Service Agent. 8 h 20 h Wipe ...

OM-498 Page 25 Return To Table Of Contents Follow the storage procedure in the engine owner ’s manual if the unit will not beused for an extended period. NOTE 8-2. Maintenance Label Ref. S-175 679-A ENGINE MAINTENANCE 8 h 1.1 l (1.2 US qt,1.94 lmp qt) Unleaded86 + Octane6.5 l (1.7 US Gal, 11.4 lmp p...

OM-498 Page 28 Return To Table Of Contents SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble Remedy No weld output. Check Amperage control setting. Check weld connections. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Age...

OM-498 Page 30 Return To Table Of Contents SECTION 10 − ELECTRICAL DIAGRAMS SC-495 297 198 016-D Figure 10-1. Circuit Diagram For Welding Generator

OM-491 Page 33 Return To Table Of Contents SECTION 11 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-drivenwelding generators. Your unit may differ from those shown. NOTE 11-1. Selecting Equipment gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 1 ...

OM-491 Page 34 Return To Table Of Contents 11-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment GroundingTerminal 2 Grounding Cable Use #10 AWG or larger insulatedcopper wire. 3 Ground Device Ground generator to systemearth ground if supplyingpower to a premises (home,shop, farm)...

OM-491 Page 35 Return To Table Of Contents 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP ...

OM-491 Page 36 Return To Table Of Contents 11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 1...

OM-491 Page 38 Return To Table Of Contents 11-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable codes and safety practic-es. Properly install and ground thisequipment according to its Owner’sManual and national, state, and...

OM-498 Page 40 Return To Table Of Contents SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure stick 12/96 − ST-151 593 Weld current starts whenelectrode touches work-piece. Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on ave...

OM-498 Page 41 Return To Table Of Contents 12-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/323/167/32 1/4 1/165/643/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/163/32 1/8 5/32 6010 & 6011 6013 7014 ...

OM-498 Page 43 Return To Table Of Contents 12-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, andthickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Lon...

OM-498 Page 45 Return To Table Of Contents 12-13. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown.A good weld bends over but doesnot break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 12-14. Troubleshooting − Porosity Porosity − small ca...

OM-498 Page 46 Return To Table Of Contents 12-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and incr...

OM-498 Page 47 Return To Table Of Contents 12-19. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resultingin holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase a...

OM-498 Page 48 Return To Table Of Contents SECTION 13 − PARTS LIST Hardware is common andnot available unless listed. 802 513-A / 802 153-B 19 25 29 22 23 28 26 27 21 32 33 30 31−Fig 13-2 34 35 36 1 6 24 3 5 4 7 8 18 17 16 15 14 13 12 9 11 10 38 39 40 41 42 43 44 Figure 13-1. Main Assembly

OM-498 Page 51 Return To Table Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-2. Generator Power Panels (Figure 13-1, Item 31) Quantity Generator Power Panel 495 298 (USA) 1 495 220 PANEL, generator power assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

TM-188 304 Page 54 Invision 354MP Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MATERIAL THICKNESS REFERENCE CHART

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 8/03 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...